Method of machining surfaces of rotor disc and grinding machine therefor

ABSTRACT

A method of manufacturing turned surfaces of a rotor disc of a gas turbine engine, including rotating the rotor disc about its central axis, rotating an abrasive grinding wheel having an outer grinding surface with a hardness greater than that of a material of the rotor disc, contacting the rotating wheel with at least one annular surface of the rotating disc, and sliding the rotating wheel along a curved cross-sectional profile of the at least one annular surface of the rotating disc.

TECHNICAL FIELD

The application relates generally to rotor discs for gas turbine engines and, more particularly, to the machining of such discs.

BACKGROUND OF THE ART

Rotors of gas turbine engines such as turbine rotors, compressor impeller rotors, rotors with separate or with integral blades, etc., typically have a rotor disc (whether integral with or separately manufactured from the blades) with turned surfaces. Such turned surfaces, and particularly those having a curved cross-sectional profiles, are typically machined by a turning method where the rotating rotor disc is put into contact with a stationary or translating point tool grinding the surface to the desired profile.

Improvements in fuel efficiency lead to gas turbine engines being run at higher temperatures. As such, harder materials are used to form the parts of the gas turbine engines. Such materials having high temperature strength and hardness are more difficult to machine. The resistance of these materials can be such as to produce, for example, excessive wear of the point tools, breakage of the point tool tips, chipping of the point tools, reduced machining speeds, and/or damaged workpiece surfaces.

SUMMARY

In one aspect, there is provided a method of manufacturing turned surfaces of a rotor disc of a gas turbine engine, the method comprising: rotating the rotor disc about a central axis thereof; rotating an abrasive grinding wheel, the abrasive grinding wheel having an outer grinding surface with a hardness greater than that of a material of the rotor disc; contacting the rotating wheel with at least one annular surface of the rotating disc; and sliding the rotating wheel along a curved cross-sectional profile of the at least one annular surface of the rotating disc.

In another aspect, there is provided a method of finishing all turned surfaces having a curved cross-sectional profile in a rotor disc of a gas turbine engine, the method comprising: retaining the rotor disc in a retaining mechanism; rotating the rotor disc about a central axis thereof with the retaining mechanism; and while rotating the rotor disc, sliding at least one rotating grinding wheel having a hardness greater than that of a material of the rotor disc along the cross-sectional profile of each of the turned surfaces having a curved cross-sectional profile without disengaging the rotating rotor disc from the retaining mechanism

In a further aspect, there is provided a grinding machine for finishing turned surfaces of a rotor disc for a gas turbine engine, the machine comprising: a retaining mechanism configured for retaining the rotor disc, the retaining mechanism being rotatable about a rotational axis corresponding to a central axis of the rotor disc; a spindle engaged to a grinding wheel, the spindle being rotatable about a rotational axis corresponding to a central axis of the grinding wheel, the grinding wheel having an outer super abrasive surface; a translating mechanism engaged to at least one of the retaining mechanism and the spindle, the translating mechanism providing a relative translational motion between the retaining mechanism and the spindle along three perpendicular axes; and a pivoting mechanism engaged to one of the retaining mechanism and the spindle, the pivoting mechanism providing a pivoting motion of the rotational axis of one of the retaining mechanism and the spindle around a pivot axis perpendicular thereto.

DESCRIPTION OF THE DRAWINGS

Reference is now made to the accompanying figures in which:

FIG. 1 is a schematic cross-sectional view of a gas turbine engine;

FIG. 2a is a schematic front view of a grinding wheel;

FIG. 2b is a schematic front cross-sectional view of the grinding wheel of FIG. 2a , taken along line B-B thereof;

FIG. 3 is a partial schematic cross-sectional view of a rotor disc which can be used in a gas turbine engine such as shown in FIG. 1 having internal and external axial surfaces being machined using a grinding wheel such as shown in FIGS. 2a -2 b;

FIG. 4 is a partial schematic cross-sectional view of the rotor disc of FIG. 3 having a curved annular surface of a face profile being machined with the grinding wheel;

FIG. 5 is a partial schematic cross-sectional view of the rotor disc of FIG. 3 having a curved surface of a pocket profile being machined with the grinding wheel;

FIG. 6 is a partial schematic cross-sectional view of the rotor disc of FIG. 3 having a curved annular surface of another face profile being machined with the grinding wheel;

FIG. 7 is a partial schematic cross-sectional view of the rotor disc of FIG. 3 having a curved surface of another pocket profile being machined with the grinding wheel;

FIG. 8 is a partial schematic cross-sectional view of the rotor disc of FIG. 3 having a curved surface of an annular groove being machined with a smaller grinding wheel;

FIG. 9 is a partial schematic cross-sectional view of the rotor disc of FIG. 3 having a curved surface of an annular lip being machined with the smaller grinding wheel;

FIG. 10 is a schematic front view of a grinding machine which can be used to machine the turned surfaces of a rotor disc such as shown in FIG. 3; and

FIG. 11 is a schematic top view of another grinding machine which can be used to machine the turned surfaces of a rotor disc such as shown in FIG. 3.

DETAILED DESCRIPTION

FIG. 1 illustrates a gas turbine engine 10 of a type preferably provided for use in subsonic flight, generally comprising in serial flow communication a fan 12 through which ambient air is propelled, a compressor section 14 for pressurizing the air, a combustor 16 in which the compressed air is mixed with fuel and ignited for generating an annular stream of hot combustion gases, and a turbine section 18 for extracting energy from the combustion gases.

The gas turbine engine 10 includes a plurality of rotors, such as for example a high pressure compressor impeller rotor 20 in the compressor section 14 and a high pressure turbine rotor 22 in the turbine section 18. Although the gas turbine 10 is shown here as a turbofan, the engine can be any other type of gas turbine engine, for example turboshaft engines and turboprop engines.

Referring to FIG. 3, a rotor disc 24 is partially shown. In the embodiment shown, the disc 24 includes blade slots 26 each sized to receive the root of a blade therein (not shown). In another embodiment, the rotor disc 24 is part of an integrally bladed rotor, i.e. where the rotor and the blades are machined as one piece.

In a particular embodiment, the rotor disc 24 is made of a material having a hardness of at least 50 HRC (Rockwell scale C). In a particular embodiment, the rotor disc 24 is made of a material selected from a nickel super alloy, a nickel-based powder metal, a metal matrix composite, and a metal matrix ceramic. Particular examples include, but are not limited to, Direct Aged Inconel 718, IN100 powder nickel alloy and ME16 powder nickel alloy.

The rotor disc 24 includes a plurality of turned surfaces, i.e. annular surfaces which have a constant cross-sectional profile around the circumference of the disc 24 and as such can be machined by a turning method. The rotor disc 24 includes a hub 28 defining an annular internal surface 30 which extends axially, i.e. parallel to the central axis C₁ of the rotor disc. The rotor disc 24 also includes an annular external surface 32 in which the blade slots 26 are defined, which also extends axially.

The turned surfaces also include a plurality of surfaces which have a curved cross-sectional profile, viewed as a curve in across-section such as that of FIG. 3. A curved turned surface 34 is defined by the face profile of one side of the rotor disc 24, defining a first annular recess 34 a in that side, extending substantially from the hub 28 to the blade slots 26. Other curved turned surfaces 36, 38 are defined by annular pockets 36 a, 38 a on each side of the hub 28. Another curved turned surface 40 is defined by the face profile of the opposite side of the rotor disc 24, defining an annular recess 40 a in that side extending adjacent the hub 28. An annular groove 42 a is defined radially outwardly from the second annular recess 40 a, and is separated therefrom by a lip 44 a. The annular groove 42 a and lip 44 a also define annular surfaces 42, 44 having curved cross-sectional profiles. In addition to or in replacement to some or to all of the above describes surfaces, the rotor may include other curved turned surfaces resulting from other face profiling, pocketing, grooving, etc.

As shown in FIG. 3, the axial annular internal and external surfaces 30, 32 may be machined by a wheel turn grinding method, through sliding engagement with an abrasive wheel 46. Referring to FIGS. 4-9, instead of being conventionally turned with a point tool, at least one of the curved turned surfaces 34, 36, 38, 40, 42, 44, on which prior machining steps may have been performed, is finished by turning using a grinding wheel 46, 146. More than one grinding wheel 46, 146 can be used, with the wheel(s) being designed to insure accurate machining of the corresponding part features and at the same time avoid collision and interference with the remainder of the disc.

Each grinding wheel 46, 146 has a hardness which is greater than that of the material of the rotor disc 24. In a particular embodiment, the grinding wheel(s) 46, 146 are super abrasive wheels including an outer super abrasive surface such as a plated, brazed or vitrified layer with cubic Boron Nitride (cBN) grits, or a plated or brazed layer with diamond grits. The core material of the grinding wheel(s) 46, 146 may vary, and include for example aluminium for lower rotational speeds and steel, titanium or carbon fiber for higher rotational speeds.

Turn grinding wheels 46, 146 are positioned and continuously fed accurately along the workpiece surface. Referring to FIG. 10, an exemplary 5-axis turn grinding machine 50 is shown, similar to a milling machine. The disc 24 is installed on a retaining mechanism 52 which retains the disc 24 in position and rotates it about a rotational axis R₁ corresponding to the central axis C₁ of the disc 24. The machine 50 also includes a spindle 54 to which is interchangeably engaged each grinding wheel 46, 146, and which is rotatable about a rotational axis R₂ corresponding to the central axis C₂ of the grinding wheel 46, 146. A translating mechanism includes a first portion 56 engaged to the retaining mechanism 52 to slide it along a Z-axis, and a second portion 58 engaged to the spindle to slide it along X and Y axes; the translating mechanism thus provides a relative translational motion between the retaining mechanism 52 and the spindle 54 along the three perpendicular axes X, Y and Z. A pivoting mechanism 60 is engaged to the retaining mechanism 52 and pivots its rotational axis R₁ around a pivot axis P perpendicular thereto.

Referring to FIG. 11, another exemplary 5-axis turn grinding machine 150 is shown, similar to a turning machine or lathe. The disc 24 is installed on a retaining mechanism 152 which retains the disc 24 in position and rotates it about a rotational axis R₁ corresponding to the central axis C₁ of the disc 24. The machine 150 also includes a spindle 154 to which is interchangeably engaged each grinding wheel 46, 146, and which is rotatable about a rotational axis R₂ corresponding to the central axis C₂ of the grinding wheel 46, 146. A translating mechanism is engaged to the spindle 154 to slide it along X and Y axes, including a linear X drive 156 received on a double linear Y drive 158. The translating mechanism includes a portion engaged to either the spindle 154 or the retaining mechanism 152 to slide it along the z-axis. A pivoting mechanism 160 is engaged to the spindle 154 and provides a pivoting motion of its rotational axis R₂ around a pivot axis P perpendicular thereto.

Other configurations for the grinding machine 50, 150 are also possible.

Referring to FIGS. 2a-2b , each wheel is defined with a particular wheel diameter D, wheel tip radius R, wheel taper angle A, wheel taper length L and wheel web thickness T. These wheel parameters are determined based on the required geometrical feature(s) of the surface to be machined and the accessibility limits to that surface. The geometrical feature(s) and accessibility limits also determine how the wheel 46, 146 is moved and the relative orientation between the wheel 46, 146 and the rotor disc 24. Wheel extensions (not shown) can be used to increase the wheel reach and avoid collision. The wheel taper angle A and length L can be adjusted to avoid interference with adjacent portions of the disc 24. The wheel tip radius R can be selected to match the required final fillet radii on the finished disc 24.

In use, curved turned surfaces of the rotor disc 24 are thus machined or finished by engaging the rotor disc 24 in a retaining mechanism 52, 152 of a grinding machine 50, 150 such as for example one of the machines of FIGS. 10-11. The rotor disc 24 is rotated about its central axis C₁ by the retaining mechanism 52, 152. The abrasive grinding wheel 46, 146 of the grinding machine 50, 150 is rotated. The rotating wheel 46, 146 is put in contact with each curved turned surface 34, 36, 38, 40, 42, 44 being machined, and slides along the curved cross-sectional profile of the surface. The relative orientation between the wheel 46, 146 and the disc 24 may be varied as the wheel slides along the cross-sectional profile and/or between the machining of two different surfaces, as required.

For example, FIGS. 4 and 6 show the use of a grinding wheel 46 to machine the curved turned surface 34, 40 defined by the face profile of the opposed sides of the rotor disc 24. The relative motion between the rotating wheel 46 and rotor disc 24 is controlled such that the wheel 46 follows the corresponding face profile of the disc 24. The wheel tip location and relative orientation between the wheel and rotor disc are controlled to avoid interference or collision with the remainder of the disc 24. The wheel geometry is also selected to allow access to the complete profile of the curved surfaces 34, 40, and may also be defined to correspond to geometrical features such as fillet radii and depths in the face profile.

FIGS. 5 and 7 shows the use of the grinding wheel 46 to machine the curved turned surfaces 36, 38 defined by the pockets 36 a, 38 a on the opposed sides of the disc hub 28. The wheel geometry may be adapted to efficiently reach the tough pocket areas which might represent a challenge for conventional turning methods using a point tool.

In the embodiment shown, the same grinding wheel 46 is used to machine the curved turned surfaces 34, 36, 38, 40 of FIGS. 4-7; in another embodiment, different wheels are used to machine at least some of the curved turned surfaces.

FIG. 8 shows the use of a smaller grinding wheel 146 to machine the curved turned surface 42 of the annular groove 42 a in one face of the rotor disc. FIG. 9 shows the use of the grinding wheel 146 to machine the inner annular surface 44 of the lip 44 a bordering the annular groove 42 a. Before contacting the rotating wheel 146 with the inner surfaces 42, 44 of the groove 42 a and lip 44 a, at least part of the rotating wheel 146 is inserted and positioned in the annular groove 42 a, and if required behind the annular lip 44 a, without contacting the rotor disc 24; the wheel 146 is thus sized according to the size of the groove 42 a to be machined. In the embodiment shown, both surfaces 42, 44 are machined using the same grinding wheel 146; in another embodiment, different grinding wheels may be used.

In a particular embodiment, all of the turned surfaces 30, 32, 34, 36, 38, 40, 42, 44 of the rotor disc 24, curved and straight, are machined using one or more grinding wheels 46, 146 in a single machining operation, without disengaging the rotor disc 24 from the retaining mechanism 52, 152 of the grinding machine. In a particular embodiment, the rotor disc 24 continuously rotates during the machining of all the turned surfaces.

During the machining process, the turn grinding wheel 46, 146 and spindle 54, 154 rotate at high speed, for example to provide a wheel surface speed of up to 50000 surface feet per minute (SFM). The wheel surface speed depends on the spindle rotational speed and on the wheel diameter.

The rotor disc 24 may rotate at a lower rotational speed, for example up to 2000 rpm. In a particular embodiment, the rotational speed of the rotor disc 24 is adjusted during the grinding to maintain a same contact surface speed between the rotor disc 24 and the grinding wheel 46, 146 as the rotating wheel 46, 146 slides along the annular surface being machined and/or as the wheel 46, 146 contacts different annular surfaces. Different portions of the rotor disc 24 having different diameters rotate at different surface speeds if the rotational speed remains constant, and adjusting the rotational speed as a function of the diameter of the annular surface being machined allows for the surface speed to remain constant or within a given range.

In the case where the rotor disc 24 includes blade slots 26, the turned surfaces may be machined with the turn grinding wheel(s) 46, 146 either before or after the slots 26 are machined in the rotor disc 24. In a particular embodiment, machining the turned surfaces prior to the blade slots 26 provides datum surface(s) used as reference for the machining of the blade slots 26.

In a particular embodiment, the use of grinding wheels 46, 146 to machine the turned surfaces of the rotor disc 24 provides for a higher quality of the machined surfaces (as opposed to turning with a point tool), which may improve the life of the rotor disc 24. The turn grinding process with grinding wheels is able to machine chips at a higher rate and more efficiently than conventional turning with a point tool, especially for hard materials such as super alloys.

The use of turn grinding wheels 46, 146 when compared to conventional single point tools generally allows for the use of harder cutting edges, an increased number of cutting edges used (along the circumference of the grinding wheel), and faster speeds of the machining operation. Since with turn grinding wheels each pass of the abrasive grit removes only a very small chip load, the machining forces and generated heat are generally limited, which may results in a better surface quality of the machined surface, which in turn may allow for a longer life of the rotor disc.

The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. For example, the machining operations described may be used with rotor discs having different geometrical features than that shown. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims. 

The invention claimed is:
 1. A method of manufacturing turned surfaces of a rotor disc of a gas turbine engine, the method comprising: rotating the rotor disc about a central axis thereof; rotating an abrasive grinding wheel, the abrasive grinding wheel having an outer grinding surface with a hardness greater than that of a material of the rotor disc; contacting the rotating wheel with at least one annular surface of the rotating disc; and while contacting the rotating wheel with the at least one annular surface of the rotating disc, sliding the rotating wheel along a curved cross-sectional profile of the at least one annular surface of the rotating disc.
 2. The method as defined in claim 1, wherein sliding the rotating wheel includes varying a relative orientation between the wheel and the disc.
 3. The method as defined in claim 1, wherein the at least one annular surface includes first and second annular surfaces of the disc, the method further comprising varying a relative orientation between the wheel and the disc while rotating the disc between sliding the rotating wheel along the curved cross-sectional profile of the first annular surface and contacting the rotating wheel with the second annular surface.
 4. The method as defined in claim 1, wherein rotating the abrasive grinding wheel includes rotating the grinding outer surface having a layer of cubic boron nitride or diamond grits.
 5. The method as defined in claim 1, wherein the rotor disc includes a plurality of annular surfaces each having a curved cross-sectional profile, the method including sliding the rotating wheel along the curved cross-sectional profile of each of the plurality of annular surfaces.
 6. The method as defined in claim 1, further comprising adjusting a rotational speed of the rotor disc to maintain a same given contact surface speed between the rotor and the wheel as the rotating wheel slides along the at least one annular surface.
 7. The method as defined in claim 1, wherein the material of the rotor disc has a hardness of at least 50 HRC.
 8. The method as defined in claim 1, wherein before contacting the rotating wheel with the at least one annular surface of the rotating disc, the rotating wheel is at least partly inserted in an annular groove of the rotor disc without contacting the rotor disc, the at least one annular surface including an inner surface of the annular groove.
 9. The method as defined in claim 8, wherein at least partly inserting the rotating wheel in the annular groove includes maneuvering the rotating wheel behind an annular lip bordering the groove, the at least one annular surface including a surface of the annular lip located within the groove.
 10. A method of finishing all curved turned surfaces in a rotor disc of a gas turbine engine, each of the curved turned surfaces having a curved cross-sectional profile, the method comprising: retaining the rotor disc in a retaining mechanism; rotating the rotor disc about a central axis thereof with the retaining mechanism; and while rotating the rotor disc, contacting at least one rotating grinding wheel having a hardness greater than that of a material of the rotor disc with each of the curved turned surfaces by sliding the at least one grinding wheel along the curved cross-sectional profile of each of the curved turned surfaces without disengaging the rotating rotor disc from the retaining mechanism, thereby finishing each of the curved turned surfaces.
 11. The method as defined in claim 10, wherein sliding the at least one rotating wheel includes varying a relative orientation between the at least one rotating wheel and the rotating disc as the at least one rotating wheel slides along the cross-sectional profile.
 12. The method as defined in claim 10, wherein sliding the at least one rotating wheel includes varying a relative orientation between the at least one rotating wheel and the rotating disc between sliding the at least one rotating wheel along the cross-sectional profile of a first one of the turned surfaces and along the cross-sectional profile of a second one of the turned surfaces.
 13. The method as defined in claim 10, further comprising adjusting a rotational speed of the rotor disc to maintain a same given contact surface speed between the rotor disc and the at least one grinding wheel as the wheel slides along each of the turned surfaces.
 14. The method as defined in claim 10, wherein sliding the at least one grinding wheel includes contacting a rotating outer surface having a layer of cubic boron nitride or diamond grits with each of the turned surfaces.
 15. The method as defined in claim 10, wherein before sliding the at least one rotating grinding wheel along the cross-sectional profile of one of the turned surfaces, the at least one rotating grinding wheel is at least partly inserted in an annular groove of the rotating rotor disc without contacting the rotor disc, the one of the turned surfaces being an inner surface of the annular groove. 